Technical data
11 Safety information
11.1 Safety regulations for working on fuel supply
11.2 Safety measures when working on vehicles with a start/stop system
11.4 Safety precautions when working on the cooling system
21.5 Safety precautions when working on ignition system
22 Identification
32.1 Engine number/engine data
33 Repair instructions
53.1 Rules for cleanliness
53.2 Foreign objects in engine
53.3 Contact corrosion
53.4 Routing and attachment of lines
53.5 Fitting radiator and condensers
6Removing and installing engine
71 Removing and installing engine
71.1 Removing engine
71.2 Separating engine and gearbox
211.3 Securing engine on engine and gearbox support
231.4 Installing engine
242 Assembly mountings
282.1 Assembly overview – assembly mountings
282.2 Removing and installing engine mounting
312.3 Removing and installing gearbox mounting
312.4 Removing and installing pendulum support
332.5 Supporting engine in installation position
342.6 Adjusting assembly mountings
372.7 Checking adjustment of assembly mountings
39Crankshaft group
401 Cylinder block (pulley end)
401.1 Assembly overview - poly V-belt drive
401.2 Assembly overview - sealing flange, belt pulley end
441.3 Removing and installing poly-V belt
461.4 Removing and installing tensioner for poly V-belt
491.5 Removing and installing vibration damper
501.6 Removing and installing engine support
521.7 Renewing crankshaft oil seal - belt pulley end
551.8 Removing and installing sealing flange on pulley end
582 Cylinder block, gearbox end
622.1 Assembly overview - cylinder block, gearbox end
622.2 Removing and installing flywheel
632.3 Removing and installing sealing flange on gearbox side
643 Crankshaft
753.1 Crankshaft dimensions
753.2 Renewing needle bearing in crankshaft
753.3 Measuring axial clearance of crankshaft
784 Pistons and conrods
804.1 Assembly overview - pistons and conrods
804.2 Removing and installing pistons
834.3 Checking pistons and cylinder bores
844.4 Separating new conrod
864.5 Checking radial clearance of conrods
874.6 Removing and installing oil spray jets
87Cylinder head, valve gear
891 Cylinder head
891.1 Assembly overview - cylinder head
891.2 Assembly overview - camshaft housing
911.3 Removing and installing cylinder head
951.4 Removing and installing camshaft housing
1001.5 Checking compression
1042 Toothed belt drive
1072.1 Assembly overview - toothed belt cover
1072.2 Assembly overview - toothed belt
1082.3 Removing and installing toothed belt guard
1122.4 Removing and installing toothed belt
1132.5 Checking valve timing
1262.6 Adjusting valve timing
1332.7 Removing toothed belt from camshaft
1513 Valve gear
1563.1 Assembly overview - valve gear
1563.2 Measuring axial play of camshaft
1583.3 Removing and installing camshaft oil seal
1593.4 Removing and installing camshaft adjuster
1663.5 Removing and installing camshaft control valve 1 N205
1843.6 Removing and installing exhaust camshaft control valve 1 N318
1843.7 Removing and installing valve stem oil seals
1853.8 Removing and installing toothed belt pulley
1964 Inlet and exhaust valves
1994.1 Checking valve guides
1994.2 Checking valves
2004.3 Valve dimensions
200Lubrication
2011 Sump, oil pump
2011.1 Assembly overview - sump/oil pump
2011.2 Engine oil:
2041.3 Removing and installing lower part of sump
2051.4 Removing and installing upper part of sump
2111.5 Removing and installing oil pump
2181.6 Removing and installing oil level and oil temperature sender G266
2192 Engine oil cooler
2212.1 Assembly overview - engine oil cooler
2212.2 Removing and installing engine oil cooler
2213 Crankcase ventilation
2233.1 Assembly overview - crankcase breather system
2233.2 Removing and installing oil separator
2244 Oil filter, oil pressure switch
2284.1 Assembly overview - oil filter/oil pressure switch
2284.2 Removing and installing oil pressure switch F1
2294.3 Removing and installing oil pressure switch for reduced oil pressure F378
2304.4 Checking oil pressure
2314.5 Removing and installing oil pressure regulating valve N428
233Cooling
2341 Cooling system/coolant
2341.1 Connection diagram - coolant hoses
2341.2 Assembly overview - engine preheater
2361.3 Checking cooling system for leaks
2371.4 Draining and adding coolant
2401.5 Removing and installing engine preheating element Z97
2492 Coolant pump, regulation of cooling system
2522.1 Assembly overview - coolant pump, thermostat
2522.2 Assembly overview - electric coolant pump
2552.3 Assembly overview - coolant temperature sender
2562.4 Removing and installing electric coolant pump
2562.5 Removing and installing coolant pump
2582.6 Removing and installing thermostat
2632.7 Removing and installing toothed belt pulley for coolant pump
2662.8 Removing and installing coolant temperature sender G62
2682.9 Removing and installing radiator outlet coolant temperature sender G83
2693 Coolant pipes
2713.1 Assembly overview - coolant pipes
2713.2 Removing and installing coolant pipes
2714 Radiator, radiator fan
2764.1 Assembly overview - radiator/radiator fan
2764.2 Assembly overview – radiator cowl and radiator fan
2784.3 Removing and installing radiator
2794.4 Removing and installing water radiator for charge air cooling circuit
2844.5 Removing and installing radiator cowl
2894.6 Removing and installing radiator fan
292Turbocharging/supercharging
2941 Turbocharger
2941.1 Assembly overview - turbocharger
2941.2 Removing and installing turbocharger
2981.3 Removing and installing charge pressure positioner V465
3042 Charge air system
3082.1 Assembly overview - charge air system
3082.2 Removing and installing charge air cooler
3112.3 Removing and installing charge pressure sender GX26
3142.4 Checking charge air system for leaks
3142.5 Removing and installing air intake pipe
316Mixture preparation - injection
3181 Injection system
3181.1 Overview of fitting locations - injection system
3182 Injectors
3232.1 Assembly overview - fuel rail with injectors
3232.2 Removing and installing fuel rail
3242.3 Removing and installing injectors
3242.4 Cleaning injectors
3313 Air filter
3333.1 Assembly overview - air filter housing
3333.2 Removing and installing air filter housing
3363.3 Removing and installing resonator for intake air
3404 Intake manifold
3424.1 Assembly overview – intake manifold
3424.2 Removing and installing intake manifold
3444.3 Removing and installing throttle valve module GX3
3474.4 Cleaning throttle valve module GX3
3484.5 Removing and installing activated charcoal filter solenoid valve 1 N80
3495 Senders and sensors
3515.1 Removing and installing fuel pressure sender G247
3515.2 Checking fuel pressure sender G247
3525.3 Removing and installing intake manifold sender GX9
3546 Engine control unit
3566.1 Removing and installing engine control unit J623
3567 High-pressure pump
3647.1 Assembly overview - high-pressure pump
3647.2 Removing and installing high-pressure pump
3687.3 Removing and installing high-pressure pipe
3708 Lambda probe
3738.1 Assembly overview - Lambda probe
3738.2 Removing and installing Lambda probe
374Exhaust system
3771 Exhaust pipes and silencers
3771.1 Assembly overview – silencers
3771.2 Separating exhaust pipes from silencers
3801.3 Removing and installing silencer
3831.4 Aligning exhaust system free of stress
3861.5 Checking exhaust system for leaks
3872 Emission control
3882.1 Assembly overview – emission control
3882.2 Removing and installing catalytic converter
3913 Secondary air system
3963.1 Assembly overview - secondary air system
3963.2 Removing and installing secondary air pump motor V101
3973.3 Removing and installing secondary air inlet valve N112
398Ignition system
4011 Ignition system
4011.1 Assembly overview - ignition system
4011.2 Test data, spark plugs
4031.3 Removing and installing ignition coils with output stage
4031.4 Removing and installing knock sensor 1 G61
4061.5 Removing and installing Hall sender
4061.6 Removing and installing engine speed sender G28
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